Endlinks tearing out of the strut mounting point are fairly common when using a larger front anti-sway bar. The tear happens at the mounting point of the endlink itself as picture here, or where the mounting bracket meets the strut housing body. The procedure described here fixes/prevents both problems.
In my case my frame tore on one side before the strut tabs tore. This was after about 4+ years of autocross (with R tires) and daily driving using a modified TRD bar. The strut tabs went about 2+ years later.
By adding the plate, the metal around the mounting hole is doubled in thickness which will prevent the endlink from ripping out of the mounting hole.
By attaching the plate to the spring perch, the entire mount is re-enforce both up and down which will prevent the base of the mount from tearing away from the strut housing/body.
The repairs pictured were completed with a MIG welder using steel welding steel wire 0.023-0.035. Ten(10) Gauge (0.1345") plate steel was using for the reinforcing plate.
Caution: The heat from welding could cause the strut insert to explode!
If you leave the strut insert inside the housing (not recommended), be very careful. The
welds described should be far enough away from the strut insert to not cause a
problem. However, it wouldn't hurt to put a cool, wet rag along the
housing to make sure the insert does not overheat and explode. I removed
the strut insert just to be safe.
Use a grinder to clean up the edges of the welds if needed/desired. This eliminates any stress risers and makes it look better.
A little black paint afterwards cleans things up nicely and helps prevent rust.
(This article is part of the MKII MR2 Autocross FAQ)
